Method and apparatus for making rail-joint members



Aug. 17', 1926. 1,596,687

i H. F. RoAcH METHOD AND APPARATUS FOR MAKING RAIL JOINT MEMBERS Filed sept'. 27, 1924 ,3 sheetsheet 1y Aug. 17, 192e.;

METHOD AND APPARAUUSFOR MAKING RAIL JOINT MEMBERS` Filed Sepp. 27, 1924 5 sheets-sheet 2 i 'l l TA/VENTO@ v H. Edda/a.

HT'TOENEKS Aug.,17,1926. 1,596,687

H. FQRoAcH. y 'METHOD AND APPARATUS FOR MAKING'RAIL Jol-Nm MEHBERS Filed sept. 27, 1924 s sheets-sheet 's Patented Aug. l?, i926.

HARRY F. ROACI-LOF ST. LOUIS, MISSOURI, l.ASSIGNOR TO REINFORCEID RAIL JOINT COMPANY, OF ST. (LOUIS, MISSOURL-A CORPORATION OF MISSOURI.

METHOD AND APPARATUS non MAKING RAIL-JOINT MEMBERS.

Application filed September 27, 1924. Serial No. 740,264.-

to permit the rails to deflect slightly and` also move upwardly at the ends of the joint under load.

The Roach joint above referred to has gone into extensive commercial use and has effected a considerable savingin the cost of maintaining railway tracks. According- 2U' ly, it has become necessary to devise a method ofmanufacture that will enable Roa-ch joints or Roach bars to bemann- ;factu1ed economically on a commercial scale and at the same time reduce to a minimum the objectionable,characteristics and unsatisfactory features of conventional methods used in the manufacture of rail joints;

1t is well known to ths'eskilled in the art that any constantsection produced by .A80 rollingis only .approximately constant, due

Lto the excessive wear of the rolls which permits the section to increase or decrease in dimensions, depending upon the character or ldesign of the element rolled. In a general way rail joints are more or less diiiicult `to roll, because they are subject to all of the drawbacks of the rail section and to many others in addition, dueY to their` irregular section and lackyof symmetry. In the com- 40 which the section is rolled are limited by danger of undercuts and the shape of the passes in which the piece is necessarily reduced are favorable to the formation of laps and seams. The section of the Roach joint member or Roach bar comesunder the class of plate orbar section and not under the class of irregular section. The platesection is not subject to all the difficulties in manufacture of rolling that ire lrecular sections are subject to, but the plate section is subject to a condition pro# duced by the rapid wearing of the rolls.

theoretical fish distance.

is Well known to those skilled in the art, a die process of pressing and forging pro mon splice'v bar, for example, the angles at' As itis a matter of common knowledge to those skilled in the art that the fish of the rail varies in dimensions fromthe beginning to the end of -a days roll, by decreasing in dimension, while the fish of the joints Vary vin dimension from the beginning to the end of a days roll, by increasing in dimension, the assembling in th-e track of these elements manufactured with varying dimensions not only occasions inconvenience, but militates towards4 the increase of maintenance of the track. Accordingly, it becomesdesirable to r-educerthis variation. to a minimum in the joint, which means the introduction of a subsequent operation, such as ,a vdie forged or pressed method.4

All rolled joints are subject to the operation of punching after rolling. The Roachjoint being of a plate section lends itself' tothe introduction of a shearing and forging method coincident with the punching operation; accordingly, a Roach bar may be produced with no more handling or oper ations than the ordinary rolled joint with the intermediate or central portion of the bar pressed or. forged kto almost an exact Furthermore, as

duc'es a fineness of surface and dimension that cannot be. produced in rolling. It also materially benefits the material of which the bar or joint member is constructed.

A Roach joint member or Roach bar maydoe made in accordance with, my present invention from a bar having approximate constant section of most any reasonable plate shape. such as Merchant bar, or it may be madeA from a bar of approximately constant section, which section is that of the intermediate portion of the conventional Roach joint; the use of the latter section occasions no more wear on the rolls, but much less work on the dies.

My preferred methodconsistsof shearing the intermediate portion and the end portions of the bar from which tlie jointl member is being formed, and then pressin to wit, beveled surfaces on the intermediate i portion of the member that bear against the il l or forging said sheared edges so asto pro uce undersides of the heads and againstthe Tip# per sides of the base flanges of the ralls, and reducedend portions that are spaced away fromv said heads and anges. An alternative method consists inv simply shearing off and forging the end portions of a`rolled bar which is of such cross -section that the 1ntermediate portion or unsheared lportion of the bar `will correspond tothe intermediate portion of a Roach-rail joint member, and

j still another method consists intaking a the intermediate portion of the bar and then simply shearing oif but not forging theend bar ofthe approximate cross section of the finished joint member, shearing and forging portions of the bar so as to reduce the height or depth of said end portions. l

v The main object ofjmy invention' is to simplify the manufacture of Roach railhjoint` members or Roach bars.

Another objectis 'to produce` a Roach bar or rail joint member whose reduced end portions'have beveled edgesinclined at sub-1 stantially the same angle as the edges of the intermediate ortion of the member which vcontact with' t eheads and the base'flangesof the rails. l

To .this end Ihave devised'a method of manufacturing a rail joint'member of the` general type referred to, which, briefly stated, is characterized by arranging a bar -or substantially oblong shaped member in a A press, punching bolt holes in said member,-v

A -shearing off Athe-'upper and lower edges of a certain portionl or portions of said member and lieveling said sheared edges in a singleoperation, the beveling of said sheared edges being effected by forging the metal insaid member.. l r Y l The apparatus that is used to unch, shear and forge the bar. from which t e rail'jojint member is formed canbe constructed in various ways without departing from thespirit of my invention, but I prefer to equip `said apparatus with a'combined shearing and forging die .fwhose female member is .provided with cutting surfaces and pressing surfaces arranged so that said,V cutting jsurfaces shear ofil the longitudinal edges of the .tol

intermediate portion and end portions of the bar, and said pressing surfaces thereafter i forge the sheared edges ofs'a'idbar in such away gas to produce a 'joint'member providedwith a-beveled edge intermediate por' tion and beveled edge reduced end portions.

Short pieces of bar of the proper length can be` fed into 4the press', one aft-er the other, or a long bar can' be fed into the ress and severed into fshort lengths simu taneously v with the operation of punching, shearing and forging the bar so as to convert it'into a finished rail joint member. Y vFigure 1 of the drawings is a side elevatibnal view of a rolled barl that I prefer t0 `har. j Figure 3 'isa View partly infront elevause in manufacturing rail joints'in accord-.- ance with my present 1nvent1on.

F'gur `2 1s a crosslsection'al view of. saldtion and partlyinr Vertical transverse section of one form of apparatus that can be used in practicing my method.l Figure tis a. view partly inside elevation and partlyy in longitudinal section-of said apparatus.

Figure 5 is a fragmentary View, the left lhand half of which is taken onthe line 55 of Figure 4,` looking downwardly, and the ure -7 lis an end view .of's'aid'rail joint preferably sheared and forgedl by cutters y and. pressingsurfaces that Qacton the intermediate portion of the bar and on the end' .portions of the bar in such a wa as to produce a rail joint member of the ind shown in Figures 6 and 7 that has an intermediate portion providedywith oppositelyfbeveled top and bottom .edgesa .that bear against the 'undersides Aof the heads of theV rails and 'against the upper sides of thebase fianges of the rails, and reducedend portions of less'deptli or height than said intermediate transversely and of` approximately `'the same fangle as the Vbeveled edges a ofthe inter- 'mediate' portion. The cutters that .act on they vend portionsof the bar are arranged ata .sli ht angle with relation to the longitudina axis of thevbar so that they will shear the longitudinal edges ofthe end portions of the bar-,along the'lines c of Figure 1,' and kthus produce a member whose vend port-ions diminish gradually in height or depth from the intermediate portion towards the end of said member. The cutters which act on t-he intermediate portion of the bar are disposed parallel with relation to the longitudinal axis of the bar so as to produce a member whose intermediate portion has straight edges, asdistinguished from the longitudinally inclined edges -onmthe end portions of said member,4 The vpressing surfaces, previously mentioned, 'that forge the sheared edgesof the bar, are so disposed that the Vmetalin the intermediate and end-,portions of the bar will be subjected to pressure in a direction' to produce oppositely-inclined, beveled edges a on the intermediate portion loo ',portion that have beveled edges b inclined llO ofthe bar and oppositely-inclined, beveled edges b on the end portions of the bar. During the operation of shearing and forging theintermediate and' end portions ofthe bar, bolt holes (l are formed `in the bar to receive .the bolts that are used to-hold the two members of the joint in engagement with the abutting' rails which said joint members embrace. Such a method enablesengaging surfaces aon the intermediate'portion of the member that contact with the heads and base flanges of the rails.

. The apparatus that I prefer to use in prac-` ticing my method' comprises a combined shearing and forging die-composed of a stationary male die member 1 and a co-operating movable female die member 2. Said apparatus also comprises punches 3 combined with the female die member 2 in such a way that they canv move relatively to said member to form bolt holes in the bar being operated on, and if desired, spring-pressed work-clamping members 4 can be associated with the punches 3 so as to facilitate the withdrawal of said punches from the bar during the upward movement of the platen or reciprocating element of the press. The bar A that I prefer to use is preferably of such cross-sectional shape that when it isl positioned upon or fed onto the stationary male member 1 of the die, it will rest square ly upon and' be firmly supported by said member during the punching, shearing and f orgingoperations. Thus, as shown invFigiires 2 and 3, the bar A is providedon its underside with a flat. central surface, and the male member 1 of the die is provided i in its top face with a cavity for receiving the central portion of the bar and two raised surfaces l, 'flat or of other desired shape,

Aat the opposite sides of said cavity that are engaged by the surfaces adjacent the edges of the bar when-the bar is positioned on said 4die member. The male member 1 of the die is carried by a stationary member B and the female member 2 is carried by a recip-A4 rocating member C that is arranged inside of areciprocating member D which is con` nected to the platen or other reciprocating element of the press. The member C is. held in longitudinal alignment with the member B bysuitable guides, and springs 5 are in` terposed between the members B and so as to separate the die members 1 and 2 at the completion of the forging operation, said springs 5 surrounding rods 6 that project upwardly -from the member B through the member C and which are provided at their upper ends with adjustable stops Tthat limit ,ing from the the upward movement ofy the' die carrying member C. The. stationary supporting structure on which the member B rests prevents the rods 6 from moving downwardly relatively 'to said member B, and upward movement of said rods relatively to the member B is prevented by heads or abutments 7a at the lower ends of said rods that fit in recesses on the underside of the member B.

The punches 3 are rigidly mounted in the member D and project downwardly from same through the member C and tubular work holding Vdevices 4 that surround the punches. Each of said work holding' devices 4 is backed up by a coiled eX- pausion spring 8 that is arranged in a pocket orrecess in the member C, the tension of' said springs 8 being such that when the member through the Das in its raised or elevated position, the

work holding devices 4 will be maintained in the position shownN 'in Figure 4, wherein it will be noted that they project -beyond the ends of the punches 3. At such times, namely, when the platen of thepress is raised, the

member D that carries the punches will be held spaced away from the upper end of the die carrying member C. If desired, means -can be provided for cooling the punches so intermediate portion andk at its end portions lwith cutting surfaces and pressing surfaces arranged so as to shear off the longitudinal edges of the intermediate. portion and end portions ofthe ba'r and then forge said sheared edges so as to bevel the same. In the die member herein illustrated two set-s of cutting edges 10 and 11 are provided, one of Said sets being arranged in advance of the other, so that said advanced set will shear off the longitudinal edges 'of the inter* mediate and end portions of the bar and the other set will thereaftervremove any rough or uneven surfaces on the sheared edges produced by displacement of the metal resultpassage of the punches through the bar, or from any other causes, The pressing surfaces withwhich the die menibers are equipped are designated in the drawing by the reference character 12, said pressing surfaces consistingof-flat, oppositelyinclined faces, as shown in Figure '3, that extend longitudinally of the die member 2 liio its

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inclined slightly with relation to the longi-` tudinal axis of the die member 2, as shown in Figure. 5, and the cutting edges and presS- Aingsurfaces that'act on the intermediate portion of the bar extend parallel to theJ longitudinal axis of the die member 2. The male member 1 of the die is of course provided with holes 3a that co-operate with the punches 3 to shear the metal engaged by the lower en ds of said punches during the downward movement of theJ platen, and'in the ap- .paratus herein illustrated the bottom face of the cavity in the upper end of the stationary die member 1 is provided with longitiulinally-disposed channels 13 that form a clearance for raised letters which'areformed l joint member, the punch carrying member D onthe underside ofthe bar A during the operationof rolling same, said channels 13 also forming `a relief for the ow of the l metal rduring the operation. ofcon'verting thebar into a railjoint member. a members are formed from a long bar that 1sl Ifthe oint severed into short lengths during the operation of punching the bolt holes and sh. ing the intermediate and end portions of the of the apparatus will be equipped with shearing devices 14 that extend transversely across the ends of thefemale die member 2 diate .portionand the end portions of the bar and bevel said'sheared edges by the'pressure exerted on same lby the pressing faces 12. Any rough edges that are'left lby the cutters lOor-any rough or uneven surfaces that are produced by thev displacement of the metal when-the punches pass through the bar are trimmed off by the cutters 11, thus insuring the sheared edges of Athe bar being smooth andeven when the inclined pressing faces 12 act on said sheared edges. During the first portion of the upward movement of the platen the work-clamping members 4 remain in engagement with the bar while the l .punches are moving upwardly out'of the bar, due, of course to the. pressure exerted on said work-clamping members by the springs 8 that back upsaid members the female member 2 of the die being restored to 4-its elevated position by the expansive force of the springs 5 that are interposed between the members Brand C of the apparatus.

i type enables such rail joint members to be4 manufactured cheaply; it produces a high character product and it produces a rail joint member whose reduced end portions have beveled edges that are disposed at substantially the same angle as the surfaces on the intermediate portion of the member that bear againstthe undersides of' the heads of the rails'an'd against the upper sides of the base flanges of the rails. j

Having thus described my invention, what I claim asl new-and, desire to secure by Letters Patent is: n

l. An apparatus `for making a member of the kind that comprises a por tion which bears against the heads and base flangesof the rails and portions that are spaced away from said -heads and flanges, consisting of a male die member, aco-operating female die member provided with cutting surfaces for'shearing off the longitudi- `nal edge portions of a'bar positioned be@ tween saidmembers, and j-'pressing surfaces lfor bevehng said' on said female die member sheared edges. l

2..An apparatus for making a rail. joint member of. the kind that comprises'an intermediate portion which bears against the heads and base flanges of the rails andreduced end portions that are. spaced away from said heads and flanges, consisting of a male die Vmember adapted tohave a bar positioned on same, aco-operating female die -member provided with cutting surfaces for shearing off the longitudinal edges of the end portions ofsaid bar, pressing surrail joint ioo faces -on said female die' member for beveling said sheared edges, and punches forv forming bolt holes in the bar..

3. An apparatus for making -a rail joint member of"the kind that comprises an in-` termediate portion which bears against the heads andbase flanges of the rails and reduced end portions that are spaced away from said heads and flanges, consisting of `a male die member adapted to have abar positioned on same, a co-operating female die member provided withcutting surfaces and pressing surfaces for .shearing and bev- -eling the edges ofthe intermediate'portion of said bar,independent-cutting surfaces f for shearing ,off the longitudinal edges'of the end portions of said bar to reduce the depth or height of same, and punches for forming bolt holes in the bar.

4e. An apparatus for making a l su joint .member of the kind that comprisiil termediate portion which bears `against the lhea/ds and base .fianges of the rails and reduced end portions that areI spaced away y from said heads and flanges, consisting of a male die'member adaptedto have a bar po;-v

sitioned onsame, a cop-'operating female i The above described method of producing member, cutting surfaces and-pressing sur#l i a ralljomtfmember of 'these-called Roach faces on said female 'member for'shearng .130

the longitudinal edges of the intermediate portion and end portions -of said barand beveling said sheared edges, and punches k for forming bolt holes in the bar.

5. An 4apparatus for .making a railljo'int member of the kind that comprises an inter- \\\mediate. portion which bears against the heads and base ianges of the rails and relongitudinal edges, a co-operating female -tions of the longitudinal edges of said bar die member providedwith cutting surfaces and pressing surfaces disposed sothat porwill be sheared 0R an'd said sheared edges thereafter beveled when said die members are brought together, and means for punchingbolt holes in the bar simultaneously with the sharingand pressing operation.

46. An apparatus for making a rail ljoint member of the kind that -comprises anintermediate portion .which bears .against the heads and base flanges of the rails and reduced end portions that are spaced away from said heads andianges, consisting of a male die member that is adapted to support a bar, a co-operating female die member having a cavity for receiving said bar when said die members are brought together, cutters on said female die member for shearing ofi' portions of the longitudinal edges ofsaid bar, oppositely-inclined -pressing faces on said female die member for forging the metal in said sheared'edges so as to bevel the same, and punches for forming bolt holes in the bar while it is positioned between l said 'die members.

7. An apparatus for making av rail joint member of the kind that' comprises an intermediate portion which bears against the heads and base flanges of the rails and reduced end portions that are spaced away from said heads and flanges, consisting of a male die member that is adapted to support a bar of substantially constant cross section that is provided with oppositely-beveled, longitudinal edges, a co-operating female die member provided with a cavity, cutting surfaces on the intermediate portion and end portions of said cavity for shearing off the longitudinal edges of the bar, inclined pressing faces adjacent said cutting surfaces for beveling the sheared edges of the bar, and means for forming bolt holes inthe bar.`

8. An apparatus for making a rail joint member of the kind that comprises an intermediate portion which' bears againstv the -headsy and base fianges of the r'ails and reduced` end Vportions that are spaced away from said heads and flanges, consisting of a4 malerdie member that is adaptedto-support a` rolled' bar provided with oppo s itelyin clined, beveled edges a co-operating female die member provided with a cavity for receiving said bar and equipped with cutting surfaces for shearing off the longitudina edges of the bar, inclined surfaces for forglng said-sheared edges, punches associated bolt holes inthe bar, and spring-pressed,` tu` Y bular work-clamping members surrounding said punches. i

9.v An apparatus for making' a rail joint member of the kind that comprises an in termediate portion which bears against the heads and base flanges of the rails and rerduced en d portions that are spaced away from said heads and flanges, consisting'of a stationary male die member provided with -a top face of irregular contour that is adapt-V ed to receive a rolled bar, a co-operating female die member provided with cutting surfaces and pressing surfaces arranged so as to shear off the longitudinal edges of the intermediate portion and end portions of said bar and vthereafter bevel the sheared edges,

HARRY F. ,RoAcH 7o" with said femaleu die member for forming" 

